Elastomer Drive Belt With Embedded Sensors for Bending Durability

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Solution Overview

Problem

Current drive belts made of elastomer materials face challenges in integrating electronic components for monitoring due to high vulcanization temperatures and operational stresses, leading to potential damage and inaccurate placement during production and use.

Innovation Solution

Embedding elongate tubular receptacles with electronic components, oriented transversely to the main bending direction, within the elastomer material, and using thermally resistant materials like polyamide or polyphenylene sulfide for the receptacles, along with a curing compound and shock-absorbing materials to protect and fix the components during vulcanization and operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electronic components are introduced before vulcanization, then they can be integrated into the belt structure, but the high vulcanization temperature of about 200°C threatens their functional ability

Engineering Contradiction:

Improveintegration reliabilityVSAvoidthermal damage to electronics

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The belt is divided into separate functional zones: electronic components are placed in isolated cavities or pockets within the belt structure, separating them from the high-temperature vulcanization zones. This segmentation allows different parts of the belt to undergo vulcanization at different times or conditions, protecting the electronics from thermal damage while maintaining structural integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Electronic components are pre-positioned in protective housings or cavities before the final vulcanization step. The belt structure is prepared with designated electronic component receptacles that are formed or prepared in advance, allowing electronics to be installed before they would be exposed to damaging temperatures during the main vulcanization process.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If electronic components are introduced before vulcanization, then integration is achieved, but flow processes during vulcanization change the position of electronic components and may destroy them

Engineering Contradiction:

Improveintegration reliabilityVSAvoidelectronic component positioning accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The belt structure incorporates localized rigid support structures or recesses specifically at electronic component locations. These local structural modifications provide precise positioning and protection for electronics in critical zones, while allowing the rest of the belt to maintain its flexibility and undergo uniform vulcanization without distorting component positions.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If electronic components are embedded in the belt body, then monitoring capability is enabled, but expansions and compressions during belt revolution severely reduce component durability

Engineering Contradiction:

Improvemonitoring capabilityVSAvoidcomponent durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

Electronic components are placed in isolated cavities or pockets within the belt structure, separating them from the high-temperature vulcanization zones. This segmentation allows different parts of the belt to undergo vulcanization at different times or conditions, protecting the electronics from thermal damage while maintaining structural integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Electronic components are surrounded by shock-absorbing or compliant materials within their housings, and cavities are designed with clearance or flexible walls, to cushion against the expansions and compressions that occur during belt revolution. This beforehand cushioning protects components from mechanical stress while allowing the belt to flex during operation.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Enables reliable and accurate installation of electronic components, protecting them from damage during vulcanization and operational stresses, allowing for condition-dependent monitoring and maintenance of drive belts.

Implementation Method 1

the electronic components are surrounded and fixed within the cavity by a curing compound, preferably a curing synthetic casting resin

Methodology Applied

Scientific EffectCuring:

Implementation Method 2

using thermally resistant materials like polyamide or polyphenylene sulfide for the receptacles

Methodology Applied

Scientific EffectThermal resistance:

Implementation Method 3

the electronic components are surrounded within the cavity by shock absorbing material

Methodology Applied

Scientific EffectShock absorption: Damping

Data Source

PatentUS11592080B2Bearing, traction or drive element made of an elastomer material having embedded electronic components

Publication Date: 2023.02.28 CONTITECH DEUTSCHLAND GMBH

AI summary

A band or belt designed as an elongate bearing, traction or drive element running around rollers or pulleys and made of an elastomer material, and preferably provided with embedded reinforcing elements or tension members extending in the longitudinal direction of the band or belt, having the following features:the band or the belt has one or more elongate tubular receptacles embedded in the elastomer material, in the cavity of which electronic components are arranged, preferably sensors, signal processing or control devices and/or transmission devices,the tubular receptacles are embedded in the elastomer material in such a way that their longitudinal axis or the direction of their greatest extent is oriented substantially transversely to the main bending direction of the band or belt.